A level product design

User Centred Design

Considering the user or target market throughout the design process

Initial Ideas

Sketches, thoughts, models, mock ups, CAD simulations, or an analysis of an existing product

Communicating ideas

Quick developmental sketching

Card modelling - low fidelity modelling

2D and 3D modelling

CAM and rapid prototyping

Formal drawings

Orthographic projections

Working drawings

Exploded views

Performance criteria to inform designing

• identify where specification criteria are met

• identify where ideas need to develop further to meet the needs, wants and values of the target market

• help structure the next iteration of ideas

• confirm features to be retained and those that need to be replaced

• specification content can be evaluated fully.

Fitness for purpose

A product must meet the design specification and solve the original design problem fully. The product must function in a reliable and expected manner and prevent the design problem from continuing.

CAD

Computer Aided Design

Advantages of CAD

• Increases productivity (faster than manual workers) whilst decreasing errors

• Often higher quality or more complex design can be achieved

• Designs can be edited / reused easily

• Designs can be easily understood

• CAD files can be easily shared

• No physical space required

• Saves time and improves accuracy

• Links to CAM seamlessly.

Anthropometrics

Refers to measurements of human beings, the human body's dimensions and sizes, and how physical features and traits are present and can vary.

Ergonomics

Refers to using anthropometric data to ensure that the product 'fits' the user, is comfortable to use, and the user interface is effective.

Iterative design process

Allows the 'think, test, analyse, rethink, test, analyse' cycle to continue endlessly (or until an idea meets all criteria).

CAM

Computer Aided Manufacture

Benefits of CAM

• is faster and more accurate than manual workers (eliminates costly errors)

• continually produces identical outcomes

• creates complex outcomes (that might not be able to be achieved using other methods)

• is cost efficient over time

• reduces the company's labour costs

• consistently replicates outcomes.

CNC

Computer Numerical Control

CIM

Computer integrated manufacturing

Digital Media

Any form of media that uses electronic devices for distribution.

Softwoods

Come from coniferous trees, which usually remain evergreen. These grow faster than hardwoods and usually have needles and pines instead of traditional leaves.

e.g- Pine, larch, cedar and spruce

Pale in colour

Darker grain

Generally more lightweight

Popular in household construction and fencing

Hardwoods

Come from deciduous trees that shed leaves in autumn. These grow slower than softwoods and are less plentiful and more expensive as a result.

e.g - oak, beech, mahogony, ash and balsa

Generally tough and durable, with close grain, with the exception of Balsa, which is very lightweight and soft, used for model making

Traditionally used for higher end furniture and furnishings

Manufactured boards

Papers, cards, MDF, plywood, chipboard, hardboard and blockboard

Polymers

1. thermosetting or thermosets

2. thermoforming or thermoplastics

Thermosetting or Thermosets

Heated, formed and cooled once

Cannot be reshaped or recycled

e.g. epoxy resins (ER), melamine formaldehyde (MF), polyester resin (PR) and urea formaldehyde (UF).

Thermoforming or Thermoplastics

Heated, shaped and cooled more than once

Much easier to recycle

e.g. polystyrene, polypropylene, PVC and acrylic.

Stock forms of materials

The standard formats in which materials are stocked and sold

Metals

Tend to be good conductors of heat and electricity, and have varying levels of ductility, malleability, flexibility, strength, durability and hardness.

Split in to 2 categories ferrous and non-ferrous metals

Ferrous Metals

Contain iron

Are magnetic and corrode

e.g. mild steel, carbon steel, cast iron and wrought iron

Will all require a protective finish applied

Non-ferrous metals

Do not contain iron

Not magnetic

Corrosion resistant

e.g. aluminium, copper, lead, zinc, tin and precious metals like gold and silver

Tend to polish well but can oxidise

Alloy

Mixtures of metals with an element to improve its properties or aesthetics

Common alloys include brass, pewter, bronze and stainless steel

Alloys can be ferrous and non-ferrous and may require protective finishing

Examples of Modern materials

Carbon fibre is a modern composite which provides high strength-weight ratio and can achieve complex shapes and forms

Glass reinforced plastic is another composite used to replace more traditional materials

Kevlar is a popular woven modern material

Examples of SMART materials

SMART materials are reactive and change when external stimuli is applied

SMA - Shape memory alloy

QTC - Quantum tunnelling composite

Thermochromic and photochromic inks, sheets or pigments

Thermochromic pigments

Thermochromic pigments change colour at specific temperatures

Examples include colour-changing novelty mugs, colour-changing spoons, battery power indicators and forehead thermometers

Photochromic pigments

Photochromic pigments change colour when exposed to light Examples include photochromic lenses for glasses, which darken when exposed to ultraviolet light

Advantages of bought in components

• Saves preparation / increases production time

− Guaranteed quality

− Less effort and skill required

− Less machinery and equipment needed

− Components bought in bulk therefore cheaper

− Standard components fit multiple products

Disadvantages of bought in components

− Supply can be unreliable

− More storage space needed for parts

− Ordering takes time, and delays occur

− No control over quality of parts

− Cannot guarantee safety

Temporary methods of joining or fastening

Methods of joining or combining which can be undone

e.g. pins, clips, catches, hinges, nuts and bolts, rivets, knock down fittings, scan fittings, keys and keyways, and press studs.

Joining or fusing materials together permanently

Welding

Brazing

Soldering

Bonding

Nailing